Bare liner bulk bag

ABSTRACT

A bare liner bulk bag and method of making the bare liner bulk bag uses a liner that is supported by a lifting system. The liner is configured to have an interior space to hold material. The lifting system includes at least one vertical strap, at least one horizontal strap and at least one bottom strap, which are connected to each other to define a volume into which the liner can be positioned without a woven fabric shell.

CROSS REFERENCE TO RELATED APPLICATION

This application is entitled to the benefit of U.S. Provisional PatentApplication Ser. No. 61/756,350, filed on Jan. 24, 2013, which isincorporated herein by reference.

BACKGROUND OF THE INVENTION

Bulk bags are used for the transportation of bulk materials. Bulk bagsare usually fabricated by stitching or sewing pieces of woven fabric.The predominant fabric used to fabricate bulk bags is polypropylenewoven fabric due to its high strength. However, the woven fabric used tofabricate the bulk bags does not block the transmission of water,moisture, or gases. Thus, for situations where water, moisture, or gasesblockage is needed, or to prevent the leakage of fine powder through thefabric or the sewing seams, liners made of plastic films or aluminumfoil film need to be inserted inside the woven fabric shell.

There are various concerns regarding conventional bulk bags with liners.The liner inside the woven fabric shell of a bulk bag can become tangledand wrinkled to prevent complete emptying of the content of the bulkbag, which not only causes wastes but also creates environmentalconcerns. The liner can break inside the woven fabric shell and exposethe content of the bulk bag to the elements without being detected fromthe outside. The liner can drop out completely or partially whendischarging the content of the bulk bag, which may cause problems to thereceiving machinery underneath. Since the woven shell is manufactured bysewing together pieces of cut fabric, debris such as cut sewing threadends and fabric fraying edges can easily get into the bulk bag andcontaminate the content of the bulk bag. In addition, fine powder canleak through the fabric and sewing needle holes and cause waste andenvironmental pollution.

SUMMARY OF THE INVENTION

A bare liner bulk bag and method of making the bare liner bulk bag usesa liner that is supported by a lifting system. The liner is configuredto have an interior space to hold material. The lifting system includesat least one vertical strap, at least one horizontal strap and at leastone bottom strap, which are connected to each other to define a volumeinto which the liner can be positioned without a woven fabric shell.

A bare liner bulk bag in accordance with embodiments of the inventioncomprises a liner configured to have an interior space to hold materialand a lifting system configured to support the liner. The lifting systemincludes at least one vertical strap, at least one horizontal strap andat least one bottom strap, which are connected to each other to define avolume into which the liner can be positioned without a woven fabricshell.

A method of making a bare bulk bag in accordance with embodiments of theinvention comprises forming a liner having an interior space to holdmaterial and forming a lifting system configured to support the liner,including connecting at least one vertical strap, at least onehorizontal strap and at least one bottom strap to each other to define avolume. The volume defined by the lifting system is used to place theliner in the lifting system without a woven fabric shell.

Other aspects and advantages of the present invention will becomeapparent from the following detailed description, taken in conjunctionwith the accompanying drawings, illustrated by way of example of theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a bare liner bulk bag in accordance withan embodiment of the invention.

FIG. 2 is a bottom view of the bare liner bulk bag shown in FIG. 1.

FIGS. 3-6 illustrate different means to attach a liner of the bare linerbulk bag to a lifting system of the bare liner bulk bag in accordancewith embodiments of the invention.

FIGS. 7 a and 7 b illustrate a method of making the liner of the bareliner bulk bag with a bottom spout in accordance with an embodiment ofthe invention.

FIGS. 8 a and 8 b illustrate another method of making the liner of thebare liner bulk bag with a bottom spout in accordance with an embodimentof the invention.

FIGS. 9 a and 9 b illustrate a method of making the liner of the bareliner bulk bag without a bottom spout in accordance with an embodimentof the invention.

FIGS. 10 a and 10 b illustrate another method of making the liner of thebare liner bulk bag without a bottom spout in accordance with anembodiment of the invention.

FIGS. 11-14 illustrate different ways to reinforce seals of the liner ofthe bare liner bulk bag in accordance with embodiments of the invention.

FIGS. 15 and 16 illustrate baffles that can be used in the liner of thebare liner bulk bag in accordance with embodiments of the invention.

FIGS. 17-20 illustrate different configurations of the horizontal andvertical straps of the lifting system of the bare liner bulk bag inaccordance with embodiments of the invention.

FIGS. 21-25 illustrate different configurations of the bottom straps ofthe lifting system of the bare liner bulk bag in accordance withembodiments of the invention.

FIGS. 26-30 illustrate different configurations of the top straps of thelifting system of the bare liner bulk bag in accordance with embodimentsof the invention.

FIGS. 31-35 illustrate different configurations of the lift strapsand/or stevedore straps of the lifting system of the bare liner bulk bagin accordance with embodiments of the invention.

FIG. 36 is a perspective bottom view of a bare liner bulk bag with abottom cover in accordance with an embodiment of the invention.

DETAILED DESCRIPTION

It will be readily understood that the components of the embodiments asgenerally described herein and illustrated in the appended figures couldbe arranged and designed in a wide variety of different configurations.Thus, the following more detailed description of various embodiments, asrepresented in the figures, is not intended to limit the scope of thepresent disclosure, but is merely representative of various embodiments.While the various aspects of the embodiments are presented in drawings,the drawings are not necessarily drawn to scale unless specificallyindicated.

The present invention may be embodied in other specific forms withoutdeparting from its spirit or essential characteristics. The describedembodiments are to be considered in all respects only as illustrativeand not restrictive. The scope of the invention is, therefore, indicatedby the appended claims rather than by this detailed description. Allchanges which come within the meaning and range of equivalency of theclaims are to be embraced within their scope.

Reference throughout this specification to features, advantages, orsimilar language does not imply that all of the features and advantagesthat may be realized with the present invention should be or are in anysingle embodiment of the invention. Rather, language referring to thefeatures and advantages is understood to mean that a specific feature,advantage, or characteristic described in connection with an embodimentis included in at least one embodiment of the present invention. Thus,discussions of the features and advantages, and similar language,throughout this specification may, but do not necessarily, refer to thesame embodiment.

Furthermore, the described features, advantages, and characteristics ofthe invention may be combined in any suitable manner in one or moreembodiments. One skilled in the relevant art will recognize, in light ofthe description herein, that the invention can be practiced without oneor more of the specific features or advantages of a particularembodiment. In other instances, additional features and advantages maybe recognized in certain embodiments that may not be present in allembodiments of the invention.

Reference throughout this specification to “one embodiment,” “anembodiment,” or similar language means that a particular feature,structure, or characteristic described in connection with the indicatedembodiment is included in at least one embodiment of the presentinvention. Thus, the phrases “in one embodiment,” “in an embodiment,”and similar language throughout this specification may, but do notnecessarily, all refer to the same embodiment.

With reference to FIGS. 1 and 2, a bare liner bulk bag 100 in accordancewith an embodiment of the invention is described. As illustrated inFIGS. 1 and 2, the bare liner bulk bag 100 includes a liner 102 and alift system 104. However, unlike conventional bulk bags with liners, thebare liner bulk bag 100 does not include a woven fabric shell. In aconventional bulk bag with a liner, the liner is inserted into a wovenfabric shell, which serves as the body or shell of the bulk bag. Sincethe bare liner bulk bag 100 does not use a woven fabric shell, the bareliner bulk bag does not suffer from the high cost of a woven fabricshell and eliminates the presence of debris associated from the wovenfabric shell, such as debris from sewing of fabric to make the wovenfabric shell and from fabric edges of the woven fabric shell. Whencompared to conventional bulk bags with liners, the bare liner bulk bag100 is easier to make, offers higher productivity, and has lowermanufacturing cost. The bare liner bulk 100 also requires less materialto manufacture, which means less material into the environment after theuseful life of the bulk bag. In addition, the liner 102 of the bare linebulk bag 100 does not wrinkle as much as a woven fabric shell somaterial in the liner can be almost completely emptied. Furthermore, anybreakage of the liner 100 can be readily observed from outside since theliner is not situated in an opaque woven fabric shell, which preventscostly damage to the material in the liner over time.

The liner 102 of the bare liner bulk bag 100 is composed of side portion106, a top portion 108, a bottom portion 110, a top spout 112 and abottom spout 114 (shown in FIG. 2). The liner portions are attached toeach other in a sealed manner so that the liner has an interior space tohold material. The liner 102 should have no needle holes or stitching soas to provide good sealing performance except on the edges or ends wherethe needle holes do not break the tightness of the liner in terms of thematerial inside.

The liner 102 is used for the filling, holding and discharging ofmaterial. The top spout 112 and the bottom spout 114 can be tied shutwith tie cords or other means. The top spout 112 is used for fillingmaterial into to the bare liner bulk bag 100 and the bottom spout 114 isused for discharging of the material from the bare liner bulk bag. Thebottom spout 114 needs be closed, e.g., tied shut, before fillingmaterial into the liner 102. The liner 102 provides water, moisture andgas blockage to protect the material inside.

The lifting system 104 of the bare line bulk bag 100 is designed tosupport the liner 102 without any woven fabric shell. The lifting system104 is composed of horizontal straps 116, vertical straps 118, which mayinclude angled vertical straps 120 (shown in FIGS. 18 and 20), liftstraps 122, top straps 124 and bottom straps 126 (shown in FIG. 2). Thelifting system 104 can also have lift loops 128 (shown in FIG. 31),stevedore straps 130 (shown in FIGS. 32-35) and a rope 132 (shown inFIG. 21). The horizontal straps 116, the vertical strap 118 and theangled vertical straps 120 are connected at their overlapping regions134 by sewing, gluing, tying or other suitable means to produce strongconnections. The various components of the lifting system 104 define avolume into which the liner 102 can be placed. When the liner 102 isfitted into the lifting system 104, the liner and the lifting system canbe free moving with respect to each other, or they can be connected toeach other by suitable means at one or more places where the liner andthe lifting system meet to secure the liner to the lifting system. As anexample, the liner 102 and the lifting system 104 can be connected toeach other by Velcro 302, as illustrated in FIG. 3. As another example,the liner 102 and the lifting system 104 can be connected to each otherby glue 402, as illustrated in FIG. 4. As another example, the liner 102and the lifting system 104 can be connected to each other by a number ofchannels, which are formed by attaching strips of fabric 502 on theliner, as illustrated in FIG. 5. As another example, the liner 102 andthe lifting system 104 can be connected to each other by a number ofties 602 that are attached to the liner, as illustrated in FIG. 6.

The lift straps 122, the lift loops 128 and/or the stevedore straps 130of the lifting system 104 are used for lifting up the bare liner bulkbag 100. The lifting system 104 is designed to hold the weight of theload and protect the liner 102 from excessive stress. The variouscomponents of the lifting system 104 can be made of polypropylene,nylon, polyester, or other suitable material of significant strength tolift the bag.

The liner 102 of the bare liner bulk bag 100 is made from tubular orflat pieces of flexible plastic, aluminum foil or other film. FIGS. 7 aand 7 b illustrate one method to make the liner 100 using seal lines inaccordance with an embodiment of the invention. If the liner material isa flat piece, it needs to be heat sealed or glued to form a tubularshape either before or after the next heat seal or glue step. The heatseal or glue step seals the liner material along the dotted lines 704.The liner material outside of the sealed lines (at the corners) is thentrimmed off. The resulting liner, when blown up or extended to a threedimensional shape, will have the appearance shown in FIG. 7 b.

FIGS. 8 a and 8 b illustrate another method of making the liner 102 inaccordance with an embodiment of the invention. In this method, the sideportion 106, the top portion 108, the bottom portion 110, the top spout112 and the bottom spout 114 of the liner 102 are preformed, as shown inFIG. 8 a. These liner components are then heat sealed or glued together,as shown in FIGS. 8 a and 8 b.

In these methods of making the liner, one or more of the liner piecesshown in FIGS. 7 a, 7 b, 8 a and 8 b can be made of multiple pieces ofliner material attached together in water tight manner. It is noted herethat the operation of heat seal or glue on the top four corners of theliner being formed shown in FIGS. 7 a and 7 b can be omitted so as toform a top opening having the same size as the side portion. The heightof the liner 102 can be made high enough so that it can be tied shutafter filling the bare liner bulk bag 100 with the desired material.Alternatively, the height of the liner 102 can be similar to the heightof the side portion so that the top of the liner is wide open afterfilling the bare liner bulk bag with the desired material. Similarly, inthe method illustrated in FIGS. 8 a and 8 b, the top portion 108 and thetop sprout 112 of the liner 102 can be omitted. In addition, the sideportion 106 of the liner 102 can be extended vertically so that it canbe tied shut after filling the bare liner bulk bag 100 with the desiredmaterial or the side portion can remain wide open on top.

The liner 102 can be mono-layered (i.e., made of single layer ofmaterial) or multiple layered (i.e., made of multiple layers ofmaterial) to achieve the required strength and blockage. If made ofmultiple liner layers, the layers can be free moving between each otheror connected to each other by suitable means, such as glue or heat seal,completely between the liner layers or at selected spots between theliner layers. A multilayer film from co-extrusion can also be used asthe liner material.

In some embodiments, the liner 102 may not have a bottom opening. If theliner 102 has the bottom spout 114, the bottom end of the bottom spoutof the liner can be closed by heat seal or glue. In other embodiments,the liner 102 may not even have the bottom spout. FIGS. 9 a and 9 billustrate one method to make the liner without the bottom spout inaccordance with an embodiment of the invention. Similar to the methodillustrated in FIGS. 7 a and 7 b, the liner material is heat sealed orglued along the dotted lines 904. However, in the embodiment illustratedin FIGS. 9 a and 9 b, the liner material is further heat sealed or gluedalong the bottom line 906 so that the bottom of the liner 102 is closed.In an embodiment, an extra piece of liner material (not shown) may beused to form the bottom of the liner. The liner material outside of thesealed lines 904 (at the top corners) is then trimmed off. The resultingliner, when blown up or extended to a three dimensional shape, will havethe appearance shown in FIG. 9 b.

FIGS. 10 a and 10 b illustrate another method of making the linerwithout the bottom spout in accordance with an embodiment of theinvention. In this method, the side portion 102, the top portion 108,the bottom portion 110 and the top spout 112 of the liner 102 arepreformed, as shown in FIG. 10 a. In this embodiment, the bottom portion110 of the liner 102 does not have any opening. These liner componentsare then heat sealed or glued together, as shown in FIGS. 10 a and 10 b.

In some embodiments, the heat or glue seal lines of the liner 102 can bereinforced. As an example, a liner patch 802 can be used to cover a heatseal line or a glue seal line 804 on the liner 102 using glue 806, asshown in FIG. 11. This type of liner patches can be used to coverseparate spots on the heat seal lines or the glue seal lines of theliner 102 or can be used to cover all of the heat or glue seal lines. Asanother example, glue 808 can be used to glue down an edge or fin 810,which is formed as a result of a heat seal or gluing of linercomponents, flat onto the liner 102, as shown in FIG. 12. As anotherexample, an overlapped heat seal 812 can be used to further attachedliner materials along a heat seal line or a glue seal line, as shown inFIG. 13. As another example, an overlapped gluing 814 can be used tofurther attached liner materials along a heat seal line or a glue line,as shown in FIG. 14.

In an embodiment, to maintain the cubic shape of the liner 102, baffles816 or 818 can be used inside the liner, as shown in FIGS. 15, 15 a, 16and 16 a. The baffles 816 and 818 include holes to facilitates flow ofmaterial to and from the corners of the liner 102 during filling anddischarging respectively. The side view of the baffles 816 and 818 areshown in FIGS. 15 a and 16 b, respectively. The baffles 816 and 818 canbe made of the same material as the liner, or another material such aspolyethylene, nylon, woven polypropylene, or a combination of thesematerials, that can be heat seal connected with the liner.

Turning now to FIGS. 17-20, variations of the lifting system 104 of thebare liner bulk bag 100 in accordance with embodiments of the inventionare illustrated. As shown in these figures, the lifting system 104 mayhave one, two or multiple horizontal straps 116. The position of thehorizontal straps 116 can be at the top, the bottom or anywhere inbetween on the bulk bag. Similar to the horizontal straps 116, thelifting system 104 may have one, two or multiple vertical straps 118 oneach side of the bulk bag. The position of the vertical straps 118 canbe at the corners of the bulk bag or anywhere else on the side of thebulk bag.

As shown in FIGS. 18 and 20, the lifting system 104 may have angledvertical straps 120. There can be one, two or more angled verticalstraps 120 on each side of the bulk bag. The angled vertical straps 120can extend from the top corners of the bulk bag, or a distance from thetop corner, of the bulk bag inwards to the middle part of the bag sideat the bottom, as illustrated in FIGS. 18 and 20. Alternatively, theangled vertical straps 120 may extend from the middle part of the bagside at the top of the bag outward to the corners, or a distance fromthe corners, of the bag side at the bottom of the bag.

Turning now to FIGS. 21-25, variations of the bottom straps 126 of thelifting system 104 in accordance with embodiments of the invention areillustrated. In FIG. 21, the ends of the bottom straps 126 are made intoloops, which can be connected together using a rope tie 132 or othermeans of connection. In FIG. 22, each bottom strap 126 extends across abottom corner of the bulk bag from one side of the bulk bag to anadjacent side of the bulk bag. In FIG. 23, each bottom strap 126 extendsfrom one side of the bulk bag to the opposite side of the bulk bag suchthat all the bottom straps overlap at a common overlapping region 134.In FIG. 24, each bottom strap 126 extends from one bottom corner to theopposite bottom corner such that all the bottom straps overlap at acommon overlapping region 134. In FIG. 25, the bottom straps 126 extendacross bottom corners of the bulk bag from one side of the bulk bag toan adjacent side of the bulk bag, similar to the bottom straps shown inFIG. 22. However, in FIG. 25, there are additional bottom straps 126that form a cross and intersect the bottom straps that extend across thebottom corners.

Turning now to FIGS. 26-30, variations of the top straps 124 of thelifting system 104 in accordance with embodiments of the invention areillustrated. The presence of the top straps 124 can hold the top of thebulk bag at a relatively rectangular shape, or any other required shape,which may be achieved by adjusting the length of each leg of the topstraps. In FIG. 26, the top straps 124 are connected to the tophorizontal strap 116 to form a diamond. In FIG. 27, the top straps 124are connected to the top horizontal strap 116 to form a cross. In FIG.28, the top straps 124 are connected to the top horizontal strap 116 andthe vertical straps 118 to form a number sign. In FIG. 29, the topstraps 124 are connected to the top horizontal strap 116 and extendacross the top corners of the bulk bag. In FIG. 30, there are no topstraps used.

Although a number of variations of the horizontal straps 116, thevertical straps 118, the angled vertical straps 120 and the top straps124 of the lifting system 104 have been illustrated and described, thereare other variations of these straps with respect to the number ofstraps and the configuration of the straps that can be used in thelifting system as long as they provide a secure support for the liner102.

Turning now to FIGS. 31-35, variations of components of the liftingsystem 104 used for lifting the bare liner bulk bag 100 in accordancewith embodiments of the invention are illustrated. In FIG. 31, the liftloops 128 are used with the lift straps 122. In FIG. 32, the stevedorestraps 130 are used with the lift straps 122, which are attached at thetop corners of the bulk bag. In FIG. 33, the stevedore straps 130 areused without the lift straps 122 such that the stevedore strapscrisscross at the top corners of the bulk bag. In FIG. 34, the stevedorestraps 130 are also used without the lift straps such that the stevedorestraps do not crisscross at the top corners of the bulk bag. In FIG. 35,the stevedore straps 130 are used with the lift straps 122 but the liftstraps are not attached at the top corners of the bulk bag.

In an embodiment, the bare liner bulk bag 100 may further include abottom cover 816, as illustrated in FIG. 36. The bottom cover 816 can beconnected to the bottom of the bulk bag 100 at various locations, suchas locations 818, 820, 822, 824, 826 and 828, by tying, Velcro or othermeans to protect the bottom of the liner 102 from damage by a pallet orother objects. The bottom cover 816 can be easily released beforedischarging material from the bulk bag.

The bare liner bulk bag 100 can be used in the following manner inaccordance with an embodiment of the invention. The bare liner bulk bag100 is first hung on a suitable structure using the four corner liftstraps 122, the lift loops 128 or the stevedore straps 130. The bottomspout 114, if any, should be tied shut or otherwise be closed. The topspout 112, if any, is then connected to the filling nozzle of a fillingmachine. Before filling the bare liner bulk bag 100, the bulk bag shouldbe inspected to make sure that the bag is properly expanded andstraightened vertically. The bare liner bulk bag 100 is then filled withthe required amount of material. The top spout 112 is then tied off orotherwise closed. The bare liner bulk bag 100 is then lifted using onlythe designated devices, such as the lift straps 122, the lift loops 128or the stevedore straps 130. The bare liner bulk bag 100 should belifted vertically, and avoid pulling on the straps in a sidewaydirection. To discharge, the bottom spout of the bare liner bulk bag 100is untied and the flat bottom of the liner is pinched open.

Although specific embodiments of the invention have been described andillustrated, the invention is not to be limited to the specific forms orarrangements of parts so described and illustrated. The scope of theinvention is to be defined by the claims appended hereto and theirequivalents.

What is claimed is:
 1. A bare liner bulk bag comprising: a linerconfigured to have an interior space to hold material; and a liftingsystem configured to support the liner, the lifting system comprising:at least one vertical strap; at least one horizontal strap; and at leastone bottom strap, wherein the at least one vertical strap, the at leastone horizontal strap and the at least one bottom strap are connected toeach other to define a volume into which the liner can be positionedwithout a woven fabric shell.
 2. The bare liner bulk bag of claim 1wherein the liner is coupled to the lifting system at one or morelocations on the lifting system to secure the liner to the liftingsystem.
 3. The bare liner bulk bag of claim 1 wherein the liner is madeof multiple pieces of liner material, the multiple pieces of linermaterial being attached to each other via seal lines.
 4. The bare linerbulk bag of claim 3 wherein the seal lines of the liner are glue seallines or heat seal lines.
 5. The bare liner bulk bag 1 wherein the linerincludes a top spout that is used to fill the liner with the material.6. The bare liner bulk bag of claim 5 wherein the liner includes abottom spout that is used to empty the liner of the material.
 7. Thebare liner bulk bag of claim 1 wherein the liner is made of pieces offlexible film that are attached to each other.
 8. The bare liner bulkbag of claim 1 wherein the at least one vertical strap includes at leastone angled vertical strap.
 9. The bare liner bulk bag of claim 1 whereinthe lifting system further includes lift straps that are attached to theat least one vertical strap.
 10. The bare liner bulk bag of claim 9further comprising a lift loop connected to each of the lift straps. 11.The bare liner bulk bag of claim 9 further comprising at least onestevedore strap connected to the lift straps.
 12. The bare liner bulkbag of claim 1 wherein the lifting system further includes at least onestevedore strap attached to the at least one vertical strap.
 13. Amethod of making a bare liner bulk bag, the method comprising: forming aliner having an interior space to hold material; and forming a liftingsystem configured to support the liner, including connecting at leastone vertical strap, at least one horizontal strap and at least onebottom strap to each other to define a volume, wherein the volumedefined by the lifting system is used to place the liner in the liftingsystem without a woven fabric shell.
 14. The method of claim 13 whereinthe forming the liner includes coupling the liner to the lifting systemat one or more locations on the lifting system to secure the liner tothe lifting system.
 15. The method of claim 13 wherein the forming theliner includes attaching multiple pieces of liner material to each otherusing a sealing process.
 16. The method of claim 15 wherein theattaching the multiple pieces of liner material to each other includesglue sealing or heat sealing the multiple pieces of liner material toeach other to form the liner.
 17. The method of claim 13 wherein theforming the liner includes forming a top spout that is used to fill theliner with the material or a bottom spout that is used to empty theliner of the material.
 18. The method of claim 13 wherein the at leastone vertical strap includes at least one angled vertical strap.
 19. Themethod of claim 13 wherein the lifting system further includes liftstraps that are attached to the at least one vertical strap.
 20. Themethod of claim 13 wherein the lifting system further includes at leastone stevedore strap attached to the at least one vertical strap.